Simulation of electrical upsetting with FORGE®

Electrical upsetting is a manufacturing process that consists in passing a high-density electric current through conduction on a metal workpiece. The heat produced by the electric current makes it possible to deform the material to the desired shape.


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This process has the advantage of allowing almost limitless formability by increasing the temperature to a point between the recrystallization and melting temperatures. The electric current will also drive a larger increase in temperature at the grain boundaries when compared with the bulk grains. This has as a consequence that the material can be deformed with ease without creating cracks.

At Osnabrück University (Germany), Transvalor and LUW IFUTEC, the institue of forming technologies, collaborate to develop FORGE® software and machine technology for the electrical upsetting process.

Electrically assisted forming

 

Benefits OF a Predictive simulation

Numerical simulation helps to optimize your process and find the right parameters to obtain optimal preforms for forging:

  • Define real parameters easily
  • Conduct sensibility studies to check the influence of inputs on the results
  • Find optimal machine settings for your production
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FORGE® provides accurate prediction of:

  • Thermal data: heating, temperature evolution, etc.
  • Electrical data: current density, electrical potential, Joule heating power, etc.
  • Effective strain distribution
  • Kinematic data: movement of the anvils, direction, height, speed, etc.
  • Shape obtained during the preform

FORGE_electrical_upsetting_grain_flow

Grain flow obtained after the final forging operation of engine valves

 

FORGE® competitive features

  • For multi-body systems, contact resistance plays a major role in the outcome. Electrically Assisted Forming is highly sensitive to contact conditions. For this reason, a special electrical contact resistance has been implemented in FORGE®.
  • The FORGE® electro-thermo-mechanical solver lets you to simulate electrical upsetting by considering all phenomena (electrical, heating and mechanics).
  • Automatic multi-material remeshing is performed at the head and near the contact with the clamp where most deformation occurs.
  • The electrical upsetting process can be part of a series of applications that you can simulate with a unique software package (more details in the video below).

 

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